spring-return pneumatic actuator - biffi...the actuator is made up of a weatherproof scotch yoke...

Installation, Operation and Maintenance Manual MAN 604A_EAC Rev. 5

July 2020

Biffi ALGAS - EACSpring-Return Pneumatic Actuator

Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center:Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – [email protected]

MAN 604A_EAC Rev. 5

Installation, Operation and Maintenance ManualJuly 2020

Revision Details

Revision Details

Revision Details

Rev. Date Description Prepared Checked Approved

4 July 2020 General update (Migration to new template)

3 March 2018 Updated chapter 2.2 Ermanni Orefici Vigliano

2 January 2017Updated applicable regulation

(chapter 1.1.1 and 1.2)Ermannid Orefici Vigliano

1 April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Orefici Vigliano

0 January 2015 Document release Ermanni Orefici Vigliano

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MAN 604A_EAC Rev. 5

Table of Contents

Installation, Operation and Maintenance Manual Table of Contents

Table of Contents

Section 1: General Warnings1.1 Generalities ................................................................................................... 1

1.1.1 Applicable Regulation ........................................................................ 11.1.2 Terms and Conditions ......................................................................... 2

1.2 Identification Plate ........................................................................................ 21.3 Description of the Actuator ........................................................................... 3

Section 2: Installation2.1 Checks to Be Carried Out on Receiving the Actuator...................................... 52.2 Storage ......................................................................................................... 52.3 Assembling the Actuator onto the Valve ....................................................... 6

2.3.1 Types of Assembly .............................................................................. 62.3.2 Valve Stem with Vertical Axis ............................................................ 112.3.3 Valve Stem with Horizontal Axis ........................................................ 15

Section 3: Operation and Use3.1 Setting of the Angular Stroke ...................................................................... 17

3.1.1 Travel Stop Screw Screwed on the End Flange of Pneumatic Cylinder .................................................................. 17

3.1.2 Stop Screw Screwed on the End Flange of Spring Container .............. 203.2 Calibration of Micro-switches (Biffi limit switch box only) ............................ 223.3 Calibration of Operating Time ..................................................................... 233.4 Preparation for Start-up .............................................................................. 24

3.4.1 Pneumatic Connections ................................................................... 243.4.2 Electrical Connections ...................................................................... 24

3.5 Start-up ...................................................................................................... 25

Section 4: Operational Tests and InspectionsOperational Tests and Inspections ....................................................................... 26

July 2020

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MAN 604A_EAC Rev. 5

Table of Contents

Table of Contents Installation, Operation and Maintenance Manual

Section 5: Maintenance5.1 Routine Maintenance .................................................................................. 275.2 Extraordinary Maintenance ......................................................................... 28

5.2.1 Replacement of Cylinder Seals ......................................................... 295.3 Lubrication of Mechanism ........................................................................... 305.4 Dismantling and Demolition ....................................................................... 34

Section 6: Troubleshooting6.1 Failure or Breakdown Research .................................................................... 35

Section 7: Layouts and Sectional Drawings7.1 Parts List for Maintenance and Replacing Procedure .................................... 36

Section 8: Spare PartsSpare Parts ........................................................................................................... 40

Section 9: Date Report for Maintenance OperationsDate Report for Maintenance Operations ............................................................. 41

July 2020

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MAN 604A_EAC Rev. 5


General Warnings

Section 1: General Warnings

General Warnings


NOTICEThe manual is an integral part of the machine, it should be carefully read before carrying out any operation and it should be kept for future references.

1.1 Generalities

Biffi Italia s.r.l. actuators are conceived, manufactured and controlled according to the Quality Control System in compliance with EN-ISO 9001 international regulation.

1.1.1 Applicable Regulation

EN ISO 12100:2010: Safety of machinery – General principles for design – Risk assessment and risk reduction

2006/42/EC: Machine directive

2014/68/EU: Directive for pressure PED equipment

2014/35/EU: Directive for low voltage equipment

2014/30/EU: Directive for the electromagnetic compatibility

2014/34/EU: Directive and safety instructions for use in hazardous area

TR TS 004/2011: Customs Union Technical Regulation (For safety of low voltage equipment)

TR TS 010/2011: Customs Union Technical Regulation (For safety of equipment and machines)

TR TS 012/2011: Customs Union Technical Regulation (For safety of equipment operated in explosive atmosphere)

TR TS 020/2011: Customs Union Technical Regulation (Electromagnetic Compatibility of Technical Products)

TR TS 032/2013: Customs Union Technical Regulation (For safety of Excess Pressure Equipment)


NOTICEBiffi Italia s.r.l. has taken every care in collecting and verifying the documentation contained in this instruction and operating manual. Nevertheless Biffi Italia s.r.l. does not provide any guarantees for this instruction manual. Biffi Italia will not be responsible for any mistakes contained in it or for any damage either accidental or due to the use of this manual. The information herein contained is reserved property of Biffi Italia s.r.l. and is subject to being modified without notice.

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General Warnings


1.1.2 Terms and Conditions

Biffi Italia s.r.l. guarantees that all the items produced are free of defects in workmanship and manufacturing materials and meet relevant current specifications, provided they are installed, used and serviced according to the instructions contained in the present manual. The warranty can last either one year from the date of installation by the initial user of the product, or eighteen months from the date of shipment to the initial user, depending on which event occurs first. All detailed warranty conditions are specified in the documentation forwarded together with the product. This warranty does not cover special products or components not warranted by subcontractors, or materials that were used or installed improperly or were modified or repaired by unauthorized staff. In the event that a fault condition be caused by improper installation, maintenance or use, or by irregular working conditions, the repairs will be charged according to applicable fees.

The warranty and Biffi Italia s.r.l. liability shall lapse in the event that any modification or tampering whatsoever be performed on the actuator.

1.2 Identification Plate

It is forbidden to modify the information and the marks without previous written authorization by Biffi Italia s.r.l.

The plate fastened on the actuator contains the following information (Figure 1).

Figure 1 Data Plate

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General Warnings


1.3 Description of the ActuatorALGAS low pressure pneumatic spring-return, are suitable for the operation of quarter-turn valves (ball valves, butterfly valves, plug valves) in both ON-OFF and modulating heavy-duty service.

The actuator is made up of a weatherproof scotch yoke mechanism transforming the linear movement of the pneumatic cylinder (or mechanical manual override, if foreseen) and of the spring into the rotary movement, which is necessary for operation.

The spring-return pack incorporates up to four springs, fully encapsulated in a factory welded cartridge: this ensures safety to personnel and simplifies assembly. The spring action can be easily changed in the field from to close in to open or from to open in to close (modular design).

The angular stroke of the yoke is adjustable between 82° and 98° by means of the external mechanical stops screwed into the end flange of the pneumatic cylinder and into the end flange of the spring-return pack. The cover of the scotch yoke mechanism is arranged for the assembly of the required accessories (position-transmitter, signaling-limit switches, positioner, etc.) by means of proper matching units. The above mentioned accessories are operated by the actuator drive sleeve.

The housing of the scotch yoke mechanism has a flange with threaded holes to fix the actuator to the valve either directly or, if required, with the interposition of an adaptor flange or a mounting bracket.

The actuator yoke has a hole with keyways suitable for the assembly of an insert bush or a stem extension. Their internal hole is machined (by Biffi or at Customer's care), according to the shape and dimensions of the valve stem.

Biffi can supply different types of control system following Customer's requirements.

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General Warnings


Code: ALGAS XXX K - YYYYY - ZZZZ - F S C

Actuator series

Scotch yoke mechanism size

Yoke shape

C Canted

S Symmetric

Spring cartridge size

Cylinder size

Internal diameter in mm

Spring action

CL Closing

OP Opening

Service

Blank Standard

QA Quick acting

Manual override

Blank No manual override

MHP Manual handpump

MHW Manual handwheel

MRHW Manual reduced handwheel

The expected lifetime of actuator is approximately 25 years.

Table 1. ALGAS single acting low pressure pneumatic actuators - Coding System

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Installation

Section 2: Installation


2.1 Checks to Be Carried Out on Receiving the Actuator

1. If the actuator arrives already assembled onto the valve, the settings of the mechanical stops and of the micro switches (if existing) has already been made by the person who assembled the actuator onto the valve. If the actuator arrives separately from the valve, the settings of the mechanical stops and of the micro switches (if existing) must be checked and, if necessary, carried out while assembling the actuator onto the valve.

2. Check that the actuator has not been damaged during transport. If necessary, repair all damages to the paint-coat, etc.

3. Check that the model, the serial number of the actuator and the performance data written on the data plate are in accordance with those described on the order acknowledgement, test certificate and delivery note.

4. Check that the fitted accessories comply with those listed in the order acknowledgement and the delivery note.

2.2 Storage(For handling and lifting procedure, please refer to Figures 6, 7 and 8).

The actuators leave the factory in excellent working conditions and with an excellent finish (these conditions are guaranteed by an individual inspection certificate); in order to maintain these characteristics until the actuator is installed on the plant, it is necessary to observe a few rules and take appropriate measures during the storage period.

1. Make sure that plugs are fitted in the air connections and in the cable entries. The plastic plugs, which close the inlets, do not have a weatherproof function, but are only a means of protection against the entry of foreign matter during transport. If long-term storage is necessary and especially if the storage is outdoors, metal plugs must replace the plastic protection plugs, which guarantee a complete weatherproof protection.

2. If the actuators are supplied separately from the valves, they must be placed onto a wooden pallet so as not to damage the coupling flange to the valve. In case of long-term storage, the coupling parts (flange, drive sleeve, insert bush) must be coated with protective oil or grease. If possible, blank off the flange by a protection disk.

3. In case of long-term storage, it is advisable to keep the actuators in a dry place or to provide at least some means of weather protection. If possible, it is also advisable, to periodically operate the actuator with filtered, dehydrated and lubricated air; after such operations all the threaded connections of the actuator and the valves of the control panel (if existing) should be carefully plugged.

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Installation


2.3 Assembling the Actuator onto the Valve

2.3.1 Types of Assembly

For coupling to the valve, the housing is provided with a flange with threaded holes according to Biffi standard tables (SCN6200; SCN6200-1; SCN6201; SCN6201-1). The number, dimensions and diameter of the holes are made in accordance with ISO 5211, but for actuator models 0.3 to 6 the holes are drilled on the centreline in order to allow an easier assembly of an intermediate flange, when required. This intermediate flange (or spool-piece) can be supplied when the valve flange cannot directly match the actuator flange in its “standard” configuration. For the biggest actuator models, the actuator flange can be machined in accordance with the valve flange dimensions.

The yoke has bored with keyways for coupling to the valve stem, the dimensions of which are according to Biffi standard tables SCN6200* and SCN6201*.

7

Ø d1 max

Ø d4

h 2

Ø d2+0.1

0

Ø d5+0.2+0.1

K +0.40

Ø d3±0.2

h 1 +0

.5 0

H m

ax

45 °

W

D10

0.3 240 93 165 M20 4 5 17 127 70 12 75.6

0.9 310 112 254 M16 8 5 19 150 86 14 96.6

1.5 360 144 298 M20 8 6 19 190 112 18 119.0

3 430 195 356 M30 8 9 23 200 157 25 167.8

6 520 250 406 M36 8 14 29 260 200 28 212.8

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Installation


Installation

Dimensions in millimeters

Actuator model Ø d1 Ø d2 Ø d3 Ø d4 N h1 h2 H max Ø d5 W K

Figure 2

Drive sleeve

N. THREADED HOLES

PCD, holes, number and size according to ISO 5211(but the holes are on centerline instead of straddle the centerline)

Top view of the scotch yoke mechanism(actuator shown in closed position)

Flow line

N.8

hol

es fl

ange

N.4

hol

es fl

ange

Table 2.

8

Ø d1 max

Ø d4

h 2

Ø d2+0.1

0

Ø d5+0.2+0.1

K+0.4

0

Ø d3±0.2

h 1 +0

.5 0

H m

ax

W D10

14 580 250 483 M36 12 10 29 340 175 45 195.8

18 680 290 603 M36 16 12 32 350 200 45 220.8

32 780 290 603 M36 16 12 32 400 220 50 242.8

35 780 315 603 M36 16 11 32 400 240 50 242.8

42 840 310 603 M36 16 12 32 400 220 50 242.8

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Installation




Figure 3

Drive sleeve

N. THREADED HOLES

PCD, holes, number and size according to ISO 5211


Flow line

Table 3.

N.1

2 ho

les

flang

eN

.16

hole

s fla

nge

9

Ø d1 max

Ø d4

h 2

Ø d2+0.1

0

Ø d3±0.2

h 1 +0

.5 0

H m

ax

Ø d5+0.2+0.1

K+0.4

0

W D10

50 800 315 698 M36 24 10 32 430 240 56 264.8

60 840 315 698 M36 24 10 32 430 240 56 264.8

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Installation


Installation



Figure 4

Drive sleeve

N. THREADED HOLES

PCD, holes, number and size according to ISO 5211


Flow line

Table 4.

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If required, for the standard models size 0.3 to 6, Biffi can supply an insert bush with unmachined bore in accordance with Biffi standard table SCN6202. On request the insert bush bore can be machined by Biffi to couple the valve stem, provided its dimensions match the maximum stem acceptance of the bush according to Biffi table TN1005, enclosed. The particular execution of the flange and bushing allow the actuator to be rotated by 90° in 4 different positions according to the Figure 5.

The Biffi insert bush with 2 external keys at 45° allows to position the keyway for the valve every 90°. Consequently actuator can be mounted in 4 positions at 90° on top of the valve. For biggest actuator models, the bore of the yoke can be machined according to the dimensions of valve stem.

Flow line

N.4

hol

es fl

ange

N.8

hol

es fl

ange

Drive sleeve

Snap ring

Housing

Insert bush

Insert bush

Adaptor flange

Drive sleeve

Standard position 1

Position 2 Position 3 Position 4

Position 2 Position 3 Position 4

Rotate insert-bush 180° around vertical-standard position (1)

Rotate insert-bush 180° around axis A-A, from position (2)

Rotate insert-bush 180° around axis A-A, from position (1)

Insert bush turned upside down

Figure 5 Insert bush + intermediate coupling flange

Table 5.

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Figure 6 Example of hook with safety latch

Figure 7

2.3.2 Valve Stem with Vertical Axis

NOTICEThe lifting and handling of the actuator must be done by qualified personnel and in accordance with the laws and regulations in force. Avoid the lifted actuator to be hung above the personnel.

!WARNINGThe actuator must be lifted by means of a suitable lifting apparatus. The weight of the actuators is indicated in the technical documentation attached to the equipment itself. For lifting and moving the actuator, use only hooks fitted with safety latch, like the one, for example, shown in Figure 6.

Lifting points: 1-2 (mandatory), 3 (balancing)

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Spring cartridgeLifting eyelet

Pneumatic cylinder

Lifting eyeletLifting point applicable for ALGAS models:

3-6-14-18-32-50-80

Lifting eyeletLifting point applicable for ALGAS models:

0.3-0.9-1.5

Figure 8

Lift ALGAS actuators (pneumatic spring-return) by means of the proper lifting points represented and indicated on actuator by sticking labels. Also refer to Figure 8 for lifting points positions.

• For lifting unbalanced loads, use ropes of different lengths or chains with adjustable length.

• Check each time the conditions of all lifting equipment used and discard it if not in perfect working order.

• Do not knot or twist the ropes so as not to reduce the lifting capacity or produce torsional effects on the load being lifted.

• Use the utmost caution and remain at a safe distance from lifted actuator unless absolutely necessary; do not stand or pass under suspended loads.

• Pay attention in putting under tension the ropes to prevent the load shifting sideways in an uncontrolled manner.

• Use slings of such length that the angles of the leg from vertical are as narrow as possible (αMAX < 20 °).

• During handling, do not transport the suspended actuator above staff members in charge of the operation.

!WARNINGDo not use the lifting eyelets on actuator to lift valve + actuator assembly.

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!WARNINGAny lifting method different from what described above is strictly forbidden. Biffi reject any responsibility for damages to goods or injuries to persons coming from wrong lifting operations.

The actuator can be assembled onto the valve flange either by using the actuator-housing flange with threaded holes, or by the interposition of an adaptor flange or a spool piece.

The actuator drive sleeve is generally connected to the valve stem by an insert bush or a stem extension.

The assembly position of the actuator, with reference to the valve, must comply with the plant requirements (cylinder axis parallel or perpendicular to the pipeline axis).

To assemble the actuator onto the valve proceed as follows:

1. Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions.

2. Bring the valve to the position related to the actuator spring operation.

3. Lubricate the valve stem with oil or grease in order to make the assembly easier. Be careful not to pour any of it onto the flange.

4. Clean the valve flange and remove anything that might prevent a perfect adherence to the actuator flange and especially all traces of grease, since the torque is transmitted by friction.

5. If an insert bush or stem extension for the connection to the valve is supplied separately, assemble it onto the valve stem and fasten it by tightening the proper stop dowels.

6. Bring the actuator to the position caused by the spring operation.

Figure 9

Lifting lugs to be used for the actuator only. Do not lift valve and actuator together.

Do not disassemble top or bottom cover spring loaded.

Porential electrostatic charge hazard.

Biffi is not liable for any personel injury due to incorrect use.

Refer to IOM.

14

M8 20

M10 40

M12 70

M14 110

M16 160

M20 320

M22 420

M24 550

M27 800

M30 1100

M33 1400

M36 1700

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Installation


7. Connect a sling to the support points of the actuator and lift it: make sure the sling is suitable for the actuator weight. When possible, it is easier to assemble the actuator to the valve if the valve stem is in the vertical position. In this case the actuator must be lifted while keeping the flange in the horizontal position.

8. Clean the actuator flange and remove anything that might prevent a perfect adherence to the valve flange and especially all traces of grease.

9. Lower the actuator onto the valve in such a way that the insert bush, assembled on the valve stem, enters the actuator drive sleeve. This coupling must take place without forcing and only with the weight of the actuator. When the insert bush has entered the actuator drive sleeve, check the holes of the valve flange. If they do not meet with the holes of the actuator flange or the stud bolts screwed into them, the actuator drive sleeve must be rotated; feed the actuator cylinder with air at proper pressure, indicated on data sheet for actuator.

10. Tighten the nuts of the connecting stud bolts evenly with the torque prescribed in the table. The stud bolts must be made of ASTM A320 L7 steel; the nuts must be made of ASTM A194 grade 2 steel. See Table 6.

11. If possible, operate the actuator to check that it moves the valve smoothly.

Thread Size Recommended Tightening Torque (Nm)

Table 6.

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2.3.3 Valve Stem with Horizontal Axis

The actuator can also be lifted to assemble directly onto the valve with stem with horizontal axis. To make a correct lifting procedure proceed as follow:

1. Connect properly the actuator lifting points 1 with chains, and connect by suitable slings the support brackets 2 and 3. See Figure 10.

Figure 10

Lifting eyelets (1)

Support brackets (2)

Lifting eyelets (1)

Support brackets (3)

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Installation


2. Balance the weight and lift the actuator until to make possible the rotation of actuator in its final mounting position, with cylinder on top, or spring container placed on top, as shown in Figure 11.

3. Clean the actuator flange and remove anything that might prevent a perfect adherence to the valve flange and especially all traces of grease.

4. Lift the actuator near to the valve in such a way that the insert bush, assembled on the valve stem, enters the actuator drive sleeve without forcing the coupling. When the insert bush has entered the actuator drive sleeve, check the holes of the valve flange. If they do not meet with the holes of the actuator flange or the stud bolts screwed into them, the actuator drive sleeve must be rotated; feed the actuator cylinder with air at proper pressure, indicated on data sheet for actuator.

5. Tighten the nuts of the connecting stud bolts evenly with the torque prescribed in the table. The stud bolts must be made of ASTM A320 L7 steel; the nuts must be made of ASTM A194 grade 2 steel.

6. If possible, operate the actuator to check that it moves the valve smoothly.

Figure 11

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Operation and Use

Section 3: Operation and Use


3.1 Setting of the Angular Stroke

It is important that the mechanical stops of the actuator (and not those of the valve) stop the angular stroke at both extreme valve position (fully open and fully closed), except when this is required by the valve operation (e.g. metal seated butterfly valves).

The travel stop screws are screwed into the end flange of the pneumatic cylinder, depending on actuator different configuration (i.e. spring to open or spring to close), and spring cartridge. The setting of the open valve position is performed by adjusting the travel stop screw on the left side of the actuator. The setting of the closed valve position is performed by adjusting the travel stop screw on the right side of the actuator.

3.1.1 Travel Stop Screw Screwed on the End Flange of Pneumatic Cylinder

For the adjustment of the travel stop screws proceed as follows:

(see Figures 12 and 13)

1. Loosen the lock nut (2) with a proper wrench (c2).

2. If the actuator angular stroke is stopped before reaching the end position (fully open or closed), unscrew the stop screw (1) by turning it anticlockwise with a proper wrench (c1), until the valve reaches the right position. When unscrewing the stop screw, keep the lock nut still with a wrench so that the sealing washer (3) does not withdraw together with the screw.

3. If the actuator angular stroke is stopped beyond the end position (fully open or closed valve), screw the stop screw by turning it clockwise until the valve reaches the right position.

4. Tighten the lock nut (2).

18

85 30 41

100 30 41

135 30 30

175 30 30

235 30 30

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Operation and Use


Figure 12

Pneumatic cylinder size Wrench c1 (mm) Wrench c2 (mm)

Table 7.

19

280 17 55

335 17 55

385 17 55

435 17 55

485 17 55

535 17 55

585 17 55

635 17 55

735 17 55

785 17 55

835 17 55

885 17 55

935 17 55

1000 17 55

1100 17 55

1200 17 55

1300 17 80

1450 17 80

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Operation and Use


Pneumatic cylinder size Wrench c1 (mm) Wrench c2 (mm)

Table 8.

Figure 13

20

1) 2)

1) 2)

MAN 604A_EAC Rev. 5


Operation and Use


Figure 14 Spring cartridge models 006 - 150

Figure 15 Spring cartridge models 200 - 15600

3.1.2 Stop Screw Screwed on the End Flange of Spring Container

For the adjustment of the travel stop screw, proceed as follows:

1. Loosen the lock nut “d”.

2. If the actuator angular stroke is stopped before reaching the end position, unscrew the stop screw “v” by turning it anticlockwise until the valve reaches the correct position.

3. If the stop-screw is too hard to be operated, reduce or remove the cylinder pressure, in order to move the mechanism far from the screw. Operate the setting-screw and then pressurize again the cylinder to reach end position.

4. If the actuator angular stroke is stopped beyond the end position, screw the stop screw by turning it clockwise until the valve reaches the correct position.

5. Tighten the lock nut, after having correctly placed the threaded seal washer “s” and “w”.

21

006 46 41

008 46 41

009 46 41

0100 46 41

0150 46 41

0200 17 60

0350 17 60

0400 17 60

0700 17 60

1100 17 80

1200 17 80

2000 17 80

2500 17 100

3800 17 100

5100 17 100

5400 17 100

8300 17 100

9600 17 100

9800 17 100

11000 17 100

15000 17 130

15600 17 130

MAN 604A_EAC Rev. 5


Operation and Use


To operate the adjustments, refer to following Tables:

Spring container size Wrench c1 (mm) Wrench c2 (mm)

Spring container size Wrench c1 (mm) Wrench c2 (mm)

Table 9.

Table 10.

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Operation and Use


3.2 Calibration of Micro-switches (If Foreseen)

(Refer to Safety Instructions Manual for limit switch box)

!WARNINGRefer only to technical documentation related to installed switch-box model.

NOTICEFor mounting interface dimension of the Limit Switch box on the cover of the actuator, please refer to TN1163V (for metric dimension) or TN1163VU (for imperial dimension).

NOTICEOperate only the micro-switch corresponding to the direction of operation being carried out, as clearly reported on the micro-switch. End of stroke microswitches should be operated before the stop of the stroke of the actuator due to mechanical stops. Adjust the relative cams properly.

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Operation and Use


3.3 Calibration of Operating Time

The calibration of the operation time is made by Biffi Italia s.r.l. according to customer requirements and to technical data sheet included in technical documentation. If necessary it’s possible to modify or to reset the operating time through the flow regulation valve placed between the control system and the pneumatic cylinder (Figure 16).

To carry out the adjustment, use an adequate Allen wrench and follow these steps (Figure 16):

• Loosen the locknut.

• Screw with a screwdriver the setting screw to increase the operation time.

• Unscrew with a screwdriver the setting screw to decrease the operation time.

• After the adjustment is over screw the locknut

The procedure is absolutely general. It is applicable both fail-to-open and fail-to-close actuators.

Figure 16 Adjustment of operating time

Pneumatic connection

Pneumatic connection

(Close) screw for decrease speed

(open) unscrew for increase speed of operation

Item 278:see operating diagram

Screwdriver

Wre

nch

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MAN 604A_EAC Rev. 5


Operation and Use


3.4 Preparation for Start-up

3.4.1 Pneumatic Connections

Connect the actuator to the pneumatic feed line with fittings and pipes in accordance to the plant specifications. They must be sized correctly in order to guarantee the necessary airflow for the operation of the actuator, with pressure drops not exceeding the maximum allowable value. The shape of the connecting piping must not cause excessive stress to the inlets of the actuator. The piping must be suitably fastened so as not to cause excessive stress or loosening of threaded connections, if the system undergoes strong vibrations.

Every precaution must be taken to ensure that any solid or liquid contaminants, which may be present in the pneumatic pipe-work to the actuator, are removed to avoid possible damages to the unit or loss of performance.

The inside of the pipes used for the connections must be well cleaned before use: wash them with suitable substances and blow through them with air or nitrogen. The ends of the tubes must be well debarred and cleaned.

Once the connections are completed, operate the actuator and check that it functions correctly, that the operation times meet the plant requirements and that there are no leaks in the pneumatic connections.

NOTICEIf necessary to mount components not in Biffi scope of supply please check the accessories mounting hole details in the documents TN 1028 ( for metric dimension) or TN 1028U (for imperial dimension)

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Operation and Use


3.5 Start-up

During the start-up of the actuator, proceed as follows:

1. Check that the pressure and quality of the air supply (filtering degree, dehydration) are as prescript. Check that the feed voltage values of the electric components (solenoid valve coils, micro-switches, pressure switches, etc.) are as prescript.

2. Check that the actuator controls work properly (remote control, local control, emergency controls, etc.).

3. Check that the required remote signals (valve position, air pressure, etc.) are correct.

4. Check that the setting of the components of the actuator control unit (pressure regulator, pressure switches, flow control valves, etc.) meet the plant requirements.

5. Check that there are not leaks in the pneumatic connections. If necessary, tighten the nuts of the pipe fittings.

6. Remove all rust and, in accordance with the applicable painting specifications, repair paint-coat that has been damaged during transport, storage or assembly.

3.4.2 Electrical Connections

Connect the electrical feed, control and signal lines to the actuator, by linking them up with the terminal blocks of the electrical components. In order to do this, the housing covers must be removed without damaging the coupling surfaces, the O-rings or the gaskets.

Remove the plugs from the cable entries.

For electrical connections use components (cable glands, cables, hoses, conduits) which meet the requirements and codes applicable to the plant specifications (mechanical protection and/or explosion-proof protection).

Screw the cable glands tightly into the threaded inlets, so as to guarantee the weatherproof and explosion-proof protection (when applicable).

Insert the connection cables into the electrical enclosures through the cable glands, and connect the cable wires to the terminals according to the applicable wiring diagram.

If conduits are used, it is advisable to carry out the connection to the electrical enclosures by inserting hoses so as not to cause anomalous stress on the housing cable entries.

Replace the plastic plugs of the unused enclosure entries by metal ones, to guarantee perfect weatherproof tightness and to comply with the explosion-proof protection codes (where applicable).

Once the connections are completed, check that the controls and signals work properly.

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MAN 604A_EAC Rev. 5


Operational Tests and Inspections

Section 4: Operational Tests and Inspections

Section 4: Operational Tests and Inspections

NOTICETo ensure the guaranteed SIL grade, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described in the Safety Manual.

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MAN 604A_EAC Rev. 5


Maintenance

Section 5: Maintenance


NOTICEBefore carrying out any maintenance operation, it is necessary to close the pneumatic feed line and exhaust the pressure from the actuator cylinder and from the control unit, to ensure safety of maintenance staff.

!WARNINGInstallation, commissioning and maintenance and repair works should be carried out by qualified staff.

5.1 Routine Maintenance

ALGAS actuators have been designed to work for long periods in the severest conditions with no need for maintenance.

NOTICEPeriodicity and regularity of inspections is particularly influenced by specific environmental and working conditions. They can be initially determined experimentally and then be improved according to actual maintenance conditions and needs.

Anyway every 2 years of operation the following is recommended:

1. Check that the actuator operates the valve correctly and with the required operating times. If the actuator operation is very infrequent, carry out a few opening and closing operations with all the existing controls (remote control, local control, emergency controls, etc.), if this is allowed by the conditions of the plant.

2. Check that the signals to the remote control desk are correct.

3. Check that the air supply pressure value is within the required range.

4. If there is an air filter on the actuator, bleed the condense water accumulated in the cup by opening the drain cock. Disassemble the cup periodically and wash it with soap and water; disassemble the filter: if this is made up of a sintered cartridge, wash it with nitrate solvent and blow through with air. If the filter is made of cellulose, it must be replaced when clogged.

5. Check that the external components of the actuator are in good conditions.

6. Check all the paint-coat of the actuator. If some areas are damaged, repair the paint-coat according to the applicable specification.

7. Check that there are no leaks in the pneumatic connections. If necessary, tighten the nuts of the pipe fittings.

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MAN 604A_EAC Rev. 5


Maintenance


5.2 Extraordinary Maintenance

If there are leaks in the hydraulic cylinder, pneumatic cylinder or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembly and seals must be replaced with reference to the follow general sectional drawing and adopting the following procedures.

!WARNINGIf the actuator can be operated, it is essential to take it to fail safe position, with the spring totally extended, otherwise the actuator should be disassembled from the valve and follow these steps.

• Remove the plug (26) from the cover of the adjustment screw (17).

• Record the length between end flange and stop-setting screw, as in Figure 17.

• Bring the adjustment screw back to the maximum (26) to let the spring loosen.

!WARNINGBefore disassembling the cylinder, make sure the above operation of spring release is done.

Figure 17

Stop setting screw cover

Stop setting screw

Plug

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MAN 604A_EAC Rev. 5


Maintenance


5.2.1 Replacement of Cylinder Seals

Refer to the following sectional drawing.

1. Measure the protrusion of the stop screw (26) with reference to the end flange (22) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.

2. Loosen the lock nut (25) and unscrew the stop screw (26) until it is removed from the end flange (22) together with the nut (25), the washer (51) and the sealing washer (50).

3. Unscrew the nuts (16) from the tie rods (18) from the side of the end flange: they must be gradually unscrewed all at the same time.

4. Slide off the end flange (22) and the tube (19).

5.2.1.1 Seals Replacement

Prior to reassemble check that the actuator components are in good conditions and clean. Lubricate all the surfaces of the parts, which move in contact with other components, by recommended grease (AGIP-ENI LCX 2/32 if seals are in NBR/Viton or Neoprene rubber, or with Aeroshell Grease 7 if the seals are in Fluorosilicon rubber). If the O-ring must be replaced, remove the existing one from its groove, clean the groove carefully and lubricate it with protective grease film.

Assemble the new O-ring into its groove and lubricate it with a protective grease film.

1. Replace the O-ring (47) of the head flange (17).

2. Replace the O-ring (49) and the guide sliding ring (48) of the piston (21).

3. Replace the O-ring (47) of the end flange (22).

4. Remove the sealing washer (50) from the stop screw (26). Carefully clean and lubricate the stop screw thread and the surface of the end flange area, on which the sealing washer is.

5. Screw the new sealing onto the stop screw until it touches the nut (25).

6. Assemble the washer (51) onto the sealing washer.

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MAN 604A_EAC Rev. 5


Maintenance


5.2.1.2 Cylinder Reassembling

1. Carefully clean the inside of the tube (19) and check that the entire surface, particularly that of the bevels, is not damaged. Lubricate the inside surface of the tube and the bevels at the ends. Slide the tube onto the piston taking care not to damage the piston O-ring (49) and the head flange O-ring (47).

2. Assemble the end flange by centering it on the inside diameter of the tube, taking care not to damage the O-ring (47).

3. Assemble the washer (24) and the nuts (16) onto the tie rods (18). Tighten the nuts to the recommended torque, alternating between opposite corners.

4. Screw the stop screw (26) into the threaded hole of the end flange until it reaches its original position (the same protrusion with reference to the flange surface). To make the operation easier feed the pneumatic cylinder with air (if possible) in order to compress the spring.

5. Check that the sealing washer (50) and the washer (51) are in contact with the end flange (22) surface.

6. Tighten the lock nut (25).

NOTICEAfter maintenance operations carry out a few actuator operations (5 - 10) to check that its movement is regular, that there is no air leakage through the seals and to to eliminate any oil residues in the air circuit, deriving from the lubrication of the seals during the replacement phase.

5.3 Lubrication of Mechanism

For normal duty the scotch yoke mechanism of the actuator is lubricated "for life". In case of high load and high frequency of operation it may be necessary to periodically restore lubrication: it is advisable to apply a generous coating of grease on the contact surfaces of the yoke and bushings, on the yoke link grooves, on the sliding blocks, on the guide bar.

For this operation it is necessary to disassemble the mechanism cover. In larger actuators the lubrication can be performed through the inspection holes of the cover after removing the plugs.

It’s necessary restore the grease into spring cartridge (for this operation remove the plug on end-flange of spring cartridge and restore a generous coating of grease).

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MAN 604A_EAC Rev. 5


Maintenance


Figure 18

Table 11.

Item Description

1 Stop setting screw

2 Spring container

3 Spring

4 Nut

5 Shoulder washer

6 Rod bushing

7 Screw

8 Housing

9 Guide bar

10 Cover gasket

11 Yoke

12 Plug

13 Bushing

14 Guide block

15 Screw

16 Nut

17 Head flange

18 Tie rod

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MAN 604A_EAC Rev. 5


Maintenance


Item Description

19 Cylinder tube

20 Piston rod

21 Piston

22 End flange

23 Lifting eyelet

24 Spring washer

25 Nut

26 Stop setting screw

27 Guide rod

28 Spring thrust flange

29 Rod bushing

30 Container rod

31 Adaptor bush

32 Washer

33 Cover

34 Screw

35 Guide block pin

36 Vent valve

37 Sliding block

38 O-ring

39 Yoke bushing

40 Retainer ring

41 Nut

42 Washer

43 Sealing washer

44 Gasket

45 Piston rod bushing

46 O-ring

47 O-ring

48 Guide sliding ring for piston

49 O-ring

50 Sealing washer

51 Washer

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MAN 604A_EAC Rev. 5


Maintenance


AGIP MU/EP/2

To be used in standard temperature conditions:

(-30 °C/+85 °C)

NLGI consistency: 2

Worked penetration: 280 dmm

ASTM dropping point: 185 °C

Base oil viscosity at 40 °C: 160 mm²/s

ISO classification: L-X-BCHB 2

DIN 51 825: KP2K - 20

Equivalent to: ESSO BEACON EP2BP GREASE LTX2SHELL ALVANIA GREASE R2ARAL ARALUB HL2CHEVRON DURALITH GREASE EP2CHEVRON SPHEEROL AP2TEXACO MULTIFAK EP2MOBILPLEX 47PETROMIN GREASE EP2

Table 12.

AEROSHELL GREASE 7 or equivalent

To be used in low temperature conditions:

(-60 °C/+65 °C)

Color: Buff

Physical state: Semi-solid at ambient temperature

Odor: Slight

Density: 966 kg/m³ at 15 °C

Flash point: >215 °C (COC) (Based on synthetic oil)

Dropping point: 260 °C (ASTM D-566)

Product code: 001A0065

Infosafe no.: ACISO GB/eng/C

The following grease is used by BIFFI for standard working temperature and suggested for re-lubrication:

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MAN 604A_EAC Rev. 5


Maintenance


5.4 Dismantling and Demolition

Before starting the disassembly a large area should be created around the actuator so to allow any kind of movement without problems of further risks created by worksite.

!WARNINGBefore disassembling the actuator it is necessary to close the pneumatic feed line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulator tank, if present.

The opposition of pneumatic supply is discharged from the cylinder by the linear movement generated from the spring releasing. It moves actuator and consequently the valve, in hits fail safe position.

If actuator is still mounted onto the valve, loosen the threaded connections between valve and actuator (screws, tie rods, nuts).

Lift the actuator using the proper lifting points (see Section 2.2 - Section 3.5).

If the actuator needs storage before demolition, see Section 2.2.

NOTICEThe demolition of the actuator both concerning any electrical and mechanical part should be made by specialized staff.

Separate the parts composing the actuator according to their nature (e.g. metallic and plastic materials, fluids etc.) and send them to differentiated waste collection sites, as provided by the laws and provisions in force.

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MAN 604A_EAC Rev. 5


Troubleshooting

Section 6: Troubleshooting

Section 6: Troubleshooting

6.1 Failure or Breakdown Research

Event Possible cause Remedy

Actuator does not work

Lack of power supply Restore it

Lack of pneumatic supply Open line interception valve

Blocked valve Repair or replace

Wrong position of the distributor of the manual hydraulic group

Restore correct position

Failure of the spring Call Biffi Italia s.r.l. Customer Service

Failure of the control group Call Biffi Italia s.r.l. Customer Service

Unexpected intervention of torque limit-device Call Biffi Italia s.r.l. Customer Service

Low supply pressure Restore (Section 1.4)

Actuator too slow

Low supply pressure Restore (Section 1.4)

Wrong calibration of flow regulator valves Restore (Section 3.6)

Bad functioning of quick exhaust valve Call Biffi Italia s.r.l. Customer Service

Wear of the valve Replace

Actuator too fast

High supply pressure Restore (Section 1.4)

Bad functioning of booster/quick exhaust valve Call Biffi Italia s.r.l. Customer Service

Wrong calibration of flow regulator valves Restore (Section 3.6)

Leakages on hydraulic or pneumatic circuits

Deterioration and/or damage to gaskets Call Biffi Italia s.r.l. Customer Service

Incorrect position of the valve

Wrong adjustment of mechanical stops Restore (Section 3.4)

Wrong warning of micro-switches Restore (Section 3.5)

Hydraulic manual pump does not work

Handle positioned on remote controlPosition the handle on the indication of the operation to make

Leakages on the check valve of the hydraulic control group

Call Biffi Italia s.r.l. Customer Service

Table 13.

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MAN 604A_EAC Rev. 5


Layouts and Sectional Drawings

Section 7: Layouts and Sectional Drawings


7.1 Parts List for Maintenance and Replacing Procedure

Figure 19 Scotch yoke Mechanism

Table 14. Parts list

Item Qty Description Material

1 4 O-ring * Fluorosilicon rubber

2 2 Yoke bushing Bronze

3 2 Retainer ring Stainless steel

4 1 Housing Carbon steel

5 1 Guide bar Alloy steel

6 1 Yoke Carbon steel

7 1 Cover gasket * SBR+Cellulose+Fillers

8 1 Guide block Carbon steel

9 1 Bushing Steel +Bz + Teflon

10 2 Sliding block Bronze

11 1 Vent valve * Stainless steel

12 12 Screw Carbon steel

13 1 Cover Carbon steel

14 1 Guide block pin Alloy steel

NOTE:* Recommended spare parts

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MAN 604A_EAC Rev. 5





Figure 20 Pneumatic cylinder



1 1 Piston rod bushing Steel + Bz + Teflon



4 1 Head flange Carbon steel

5 16 Nut Carbon steel ASTM A194 gr. 7

6 8 Tie rod Alloy steel ASTM A320 gr. 7

7 1 Cylinder tube Nickel plated carbon steel ASTM A333 gr. 6

8 1 Piston rod Alloy steel

9 1 Piston Carbon steel

10 1 End flange Carbon steel

11 1 Liftting eyelet Carbon steel

12 2 Spring washer Carbon steel

13 1 Washer Carbon steel

14 1 Sealing washer * ELVAX

15 1 Nut Carbon steel

16 1 Stop setting screw Carbon steel

17 1 Guide sliding ring for piston * Teflon + graphite



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MAN 604A_EAC Rev. 5




Figure 21 Spring cartridge





3 1 Sealing washer * ELVAX

4 1 Stop setting screw Nitrided carbon steel

5 1 Spring container (welded assembly) Carbon steel

6 1 Spring Carbon steel


8 1 Shoulder washer Alloy steel

9 1 Rod bushing Steel + Bz + Teflon

10 1 Guide rod Alloy steel (chromium plated)

11 1 Spring thrust flange Carbon steel

12 1 Rod bushing Steel + Bz + Teflon

13 1 Container rod Alloy steel (chromium plated)

14 1 Guide support Carbon steel

15 1 Plug Stainless steel + FKM rubber


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MAN 604A_EAC Rev. 5





Figure 22 Assembly kit



1 4 Screw Alloy steel

2 2 Gasket * SBR + Cellulose + fillers

3 1 Plug Carbon steel

4 1 Adaptor bush Alloy steel



7 4 Washer Copper


Spring to close assembly Spring to open assembly

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MAN 604A_EAC Rev. 5


Spare Parts

Section 8: Spare Parts

Section 8: Spare PartsFor spare parts order to the relevant Biffi office please make reference to Biffi order confirmation concerning all the supply, and serial number of the actuator (Section 1.2) for any specific spare part for a specific actuator model.

Please send every spare parts request to :

Biffi Italia s.r.l. – Spares Office

Tel.: 0523-944523

Fax: 0523-941885

E-mail: [email protected]

Please specify :

1. Actuator model

2. Biffi acknowledgement

3. Spare parts code

4. Quantity

5. Transport condition

6. Involved people

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MAN 604A_EAC Rev. 5


Date Report for Maintenance Operations

Section 9: Date Report for Maintenance Operations

Section 9: Date Report for Maintenance Operations

Last maintenance operation date: (in factory, on delivery):

……… exec. by : …………

……… exec. by : …………

……… exec. by : …………

Next maintenance operation date: ……… exec. by : …………

……… exec. by : …………

……… exec. by : …………

Start-up date: ……… (in factory, on delivery) …………

………… (on plant) …………

For complete list of sales and manufacturing sites, please visit www.biffi.it or contact us at [email protected]

Biffi Italia s.r.l. Strada Biffi 16529017 Fiorenzuola d’Arda (PC)ItalyT +39 0523 944 411

VCIOM-15304-EN ©2020 Biffi. All rights reserved.

The contents of this publication are presented for information purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.

spring-return pneumatic actuator - biffi...the actuator is made up of a weatherproof scotch yoke...

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